Smokeable Material Recovery

ABSTRACT

A machine for making smoking articles that include filters ( 24 ) such as filter cigarettes, has fabrication stations configured in a production line to perform sequential steps in their manufacture, and an inspection station to identify those of the smoking articles that are to be rejected as a result of not meeting a quality control criterion. A filter removal device ( 31 ) is arranged on the production line to remove the filters ( 24 ) from the smoking articles identified for rejection at the inspection station.

FIELD

This specification relates to a machine for making smoking articles suchas cigarettes that include filters, for use in recovering smokeablematerial from the smoking articles rejected during manufacture.

BACKGROUND

It has previously been proposed to recover tobacco from cigarettes thatare rejected due to manufacturing faults. Conventionally, tobacco rodsare attached to filter segments by tipping paper in a cigarette makingmachine and the cigarettes manufactured in this way pass around aninspection drum where they are inspected for manufacturing faults.Cigarettes that are faulty are caused to drop from the inspection druminto a hopper below. Then, offline, the rejected cigarettes have theirfilters removed and the paper wrapper around the tobacco rod is cut inorder to release the tobacco so that it can be recovered for re-use inthe cigarette making machine. This process is time consuming andrequires the rejected cigarette to be lined up after leaving the hopperso that the filters can be removed and the rods opened to release thetobacco.

SUMMARY

An embodiment of a machine for making smoking articles that includefilters, described in more detail hereinafter, comprises a plurality offabrication stations configured in a production line to performsequential steps in their manufacture, an inspection station on theproduction line to receive the so manufactured smoking articlessequentially and to identify those of the smoking articles that are tobe rejected as a result of not meeting a quality control criterion, anda filter removal device on the production line to remove the filtersfrom the smoking articles identified for rejection at the inspectionstation.

Also described is a method of using the machine in a process to recoversmokeable material

A filter removal device is also described which can be retrofitted tothe production line such as to remove the filters from the smokingarticles identified for rejection at the inspection station.

BRIEF DESCRIPTION OF THE DRAWINGS

In order that the invention may be more fully understood an embodimentthereof will now be described by way of example with reference to theaccompanying drawings in which:

FIG. 1 is a schematic side view of a cigarette making machine;

FIG. 2 illustrates successive stages during the manufacture of filtercigarettes with the machine shown in FIG. 1; and

FIG. 3 illustrates the removal of a filter from a rejected cigarette andthe cutting of its wrapper.

DETAILED DESCRIPTION

Referring to FIG. 1, a cigarette making machine is illustrated which inwhich smoking articles in the form of filter cigarettes are manufacturedin a series of fabrication steps performed at fabrication stations alonga production line. The fabrication steps include attaching rods oftobacco to opposite ends of a filter rod, cutting the filter rod toproduce two cigarettes back-to-back, re-aligning the cigarettes carryingout a quality control inspection, rejecting unacceptable cigarettes andpassing accepted cigarettes for packaging. The machine illustrated inFIG. 1 can be considered as a modification of a conventional machinesuch as the Hauni Max manufactured by Hauni Maschinenbau AG of HamburgGermany, in which filters are removed from rejected cigarettes online.

As shown in FIG. 1, successive lengths of tobacco rod 1 manufactured bya rod making machine are fed from a hopper into axially extendinggrooves 2 on the surface of the inlet drum 3 by means of a spider (notillustrated in FIG. 1 in order to simplify the explanation). Asillustrated in FIG. 2A, each of the tobacco rods 1 has a lengthcorresponding to two cigarettes. The tobacco rods 1 may comprise tobaccoor like smokeable material wrapped in a paper wrapper, as discussed inmore detail hereinafter.

The rods 1 on drum 3 are fed into corresponding grooves 2 of a cutterdrum 4 where they pass a rotary cutter blade 5 that cuts the rods 1 inhalf as illustrated in FIG. 2B to form rods 1,1′. The cut rods then passonto grooves 2 of a spacer drum 6 which is driven in synchronism withthe cutter drum 4. A spacer device 7 separates the cut rods 1, 1′illustrated in FIG. 2C and passes them onto a filter receiving drum 8that also has grooves 2. The various rods can be held in the grooves 2of the drums described herein by negative air pressure through the useof a pumping system (not shown).

The tobacco rods 1, 1′ spaced are apart by a distance sufficient toreceive a length of filter rod 9 fed onto the filter receiving drum 8from filter inlet drum 10 that receives successive filter rods 8 from ahopper (not shown) fed in the direction of arrow B. The filter rods 9may comprise cellulose acetate tow wrapped in a plug wrap or may includeother or additional filter material such as a Dalmatian filter segment,flavourant for example in frangible capsules or adsorbant such asparticles of activated carbon.

The resulting configuration of tobacco rods 1, 1′ and filter rod 9 isillustrated in FIG. 2C. This arrangement of aligned rods is thentransferred to a tipping drum ii that is driven in synchronism with drum8 and a swashplate (not shown) ensures that the rods 1, 9 and 1′ abutone another.

Then, a cut length of tipping paper 12 as applied to the filter rod 8 soas to overlap its ends and join the rods 1, 1′, 8 together asillustrated in FIG. 2D. The tipping paper is fed as a web 13 from asupply roll (not shown) in the direction of arrow C onto an applicatorroller 14 after having been passed over a curling plate and havingadhesive applied in a manner well known per se and not illustrated inFIG. 1 in order to simplify the explanation. A cutter roller 15 withblades 16 cuts the continuous web of tipping paper 13 into individualsegments 12 for each pair of cigarettes as illustrated in FIG. 2D. Theaction of the drum 11 is to roll the tipping paper around the coaxialarrangement of rods 1, 1′, 9 shown in FIG. 2D so that they become joinedby the glued tipping paper segment 12 to provide the combined rodarrangement illustrated in FIG. 2E.

The combined rod arrangement 1, 1′, 9 is then transferred to aventilation forming station that comprises a synchronously driven drum17 with an associated laser 18 which burns ventilation holes into thefilter and/or tobacco rods 1,9,1′. The ventilated rods are then passedby a feeder roller 19 to a cutting station comprising a roller 20 androtary cutter blade 21 which cuts the joined rods in half by a rotarycutter blade 20 to provide a pair of cigarettes 22, 22′ with tobaccorods 23, 23′ and filter segments 24, 24′ respectively arranged back-toback. The cut cigarettes 22, 22′ are then fed onto the periphery of adrum 25 shown in FIG. 1 that is driven in synchronism with drum 20 atwhich the cigarettes 22′ are flipped over to be aligned with cigarettes22 as illustrated in FIG. 2G.

The aligned cigarettes 22, 22′ are then fed into grooves 2 of feederdrum 26 that rotates in synchronism with drum 25 so that the alignedcigarettes are fed successively through an inspection station comprisingan inspection drum 27 at which a camera 28 or other optical detectorcarries out an inspection of the quality of the thus manufacturedcigarettes received in grooves 2 of the drum 26. The detector 28 feedsdata to a processor P which compares it with stored informationcorresponding to quality control criteria so as to control a divertergate G depending on the outcome, so that the cigarettes which meet thequality control criteria are fed in an accept path onto outlet drum 29driven in synchronism with drum 26 and then pass in the direction ofarrow D onto an output conveyor (not shown) for packaging. The divertergate G diverts rejected cigarettes so that they continue on a rejectpath around the inspection drum 26 and transfer onto a reject drum 30towards a filter removal device in the form of a rotary blade 31, whichis configured to cut off the filter 24 from the tobacco rod 23 of therejected cigarettes. The diverting action of the gate G may beimplemented or assisted by controlling or releasing the negativepressure that retains the cigarettes 22 in the grooves 2 on theinspection drum.

The processor P may also receive quality control data from other testsperformed on the cigarettes whilst they pass along the production line,which can used to control the diverter gate G. For example, thecigarettes may be subject to a pressure test as they pass around theinspection drum 27, in which air is pumped into one end and the pressuredrop through the rod is measured. If the pressure drop is too high ortoo low, this indicates a bad join between the tobacco rod and filter ofthe cigarettes 22, 22′ such that the cigarette should be rejected. Alsoan optical detector (not shown) may be provided to detect loose endswhere not enough tobacco fills the rod, or strands of tobacco that areprotruding from the rod ends.

Referring to FIG. 2H, it can be seen that rejected cigarette 22″ has afilter 23″ that includes a fault 32 at its mouth end which will beunacceptable to the user.

The rejected cigarettes that pass cutter 31 abut against a transverseguide 33 and so are accurately aligned axially. As a result, the cutterblade 31 can accurately cut the filter 24″ from the tobacco rod 23″ asshown in FIG. 2J through the tobacco rod whilst in situ on the rejectdrum 30. The cut filter 24″ falls along a first reject path 34 whereasthe tobacco rod 23″ falls along a second reject path 36 as shown in FIG.2J.

Thus, the filter 24″ can be cut from the tobacco rod towards the end ofthe tobacco rod, with the result that the filter remains intact and isnot itself cut open by the filter removal process. A small length oftobacco rod remains on the filter so that the end of the filter is notopened by the cutting process. This ensures that there is no release ofthe contents of the filter as a result of the cutting process, whichcould otherwise contaminate the region of the cutting blade 31, forexample if the filter contains carbon granules or a ruptured liquidcontaining capsule. Furthermore, the accurate cutting of the tobacco rod19″ close to the filter ensures that there is little wastage of tobaccoin the recovery process to be described below.

Referring to FIG. 3, the filters 24″ cut by the cutter 32 pass into arejection hopper 36. The tobacco rods 23″ cut by the cutter 31 howeverfall onto a conveyor belt 37 which moves in the direction of arrows 38,39. A guide 40 shown in dotted outline ensures that the tobacco rods 23″are aligned axially in a guide channel 41 so that they are driven past arotary cutting blade 42. The blade 42 cuts the paper wrapper 43 for eachrod 23″ longitudinally so as to release tobacco 44 from the wrapper 43.The tobacco 43 can fall into a chute 45 through an appropriately sizedmesh 46 in order to become separated from the paper wrapper 44.Alternatively, the mix of wrappers 43 and tobacco 44 may be fed into acentrifuge (not shown) in order to separate them from one another.Alternatively a cyclone (not shown) can be used. Also, a combination ofthese separation techniques can be carried out with advantage.

The reclaimed tobacco 44 can then be re-used in the manufacture oftobacco rods 1 and thereby minimise waste. Moreover, the tobacco 44 isnot contaminated with any of the filter components which may causedetrimental taste or chemical effect if smoked in conjunction with thetobacco.

Many modifications and variations to the described on-line filterremoval will be evident to those skilled in the art. For example thedescribed process may be used for smoking articles other than cigarettesand as used herein, the term “smoking article” includes smokeableproducts such as cigarettes, cigars and cigarillos whether based ontobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco ortobacco substitutes and also heat-not-burn products.

Also on-line filter removal devices other than a rotary cutting bladecould be used. For example a wedge shaped member could be used toaxially deform the filter to snap it away from the tobacco rod. Also, areciprocating blade could be used.

In another modification, the cigarettes that are rejected by theprocessor P may be have their filters cut whilst on the inspection drumrather than use a rejection drum separate from the inspection station.

Also, further quality control measures may be included. For example, thecombination of rods shown in FIG. 2C may be rejected either afteroptical detection or in terms of their combined weight e.g. at drum 8,so as to detect whether a filter rod 8 was successfully placed betweenthe tobacco rods 1, 1′.

It will also be appreciated that the various steps of productiondescribed with reference to FIG. 2 can be altered and modified. Forexample addition drums may be included in the production line to allowadditional manufacturing steps to be performed.

Also, it will be understood that the cutting blade 31 and thearrangement shown in FIG. 3 can be included in a bespoke cigarettemaking machine or can be retro-fitted to a machine already commissionedfor use in a factory in order to provide an improved tobacco recoveryfrom rejected smoking articles by on-line filter removal.

An advantage of the described example of online filter removal is thatthere is less likelihood of contamination of the tobacco with substancesincorporated in the filter during the recovery of tobacco if thematerial is recovered as compared with prior offline methods, forexample, maceration by a series of fans or slitting of the completecigarette length will expose the contents of the filter to the tobaccorod, which in some instances, may lead to a detrimental effect on thenature of the reclaimed tobacco, for instance, altering the tasteprofile due to inclusion of unwanted particles of capsule or carbon.This is overcome by the described online filter removal in which thefilter is accurately cut from the tobacco rod online.

In order to address various issues and advance the art, the entirety ofthis disclosure shows by way of illustration various embodiments inwhich the claimed invention(s) may be practiced and provide for superiormachines for making smoking articles and methods of their use andretrofitting for use for making such smoking articles. The advantagesand features of the disclosure are of a representative sample ofembodiments only, and are not exhaustive and/or exclusive. They arepresented only to assist in understanding and teach the claimedfeatures. It is to be understood that advantages, embodiments, examples,functions, features, structures, and/or other aspects of the disclosureare not to be considered limitations on the disclosure as defined by theclaims or limitations on equivalents to the claims, and that otherembodiments may be utilised and modifications may be made withoutdeparting from the scope and/or spirit of the disclosure. Variousembodiments may suitably comprise, consist of, or consist essentiallyof, various combinations of the disclosed elements, components,features, parts, steps, means, etc. In addition, the disclosure includesother inventions not presently claimed, but which may be claimed infuture.

1. A machine for making smoking articles that include filters,comprising a plurality of fabrication stations configured in aproduction line to perform sequential steps in their manufacture, aninspection station on the production line to receive the so manufacturedsmoking articles sequentially and to identify those of the smokingarticles that are to be rejected as a result of not meeting a qualitycontrol criterion, and a filter removal device on the production line toremove the filters from the smoking articles identified for rejection atthe inspection station.
 2. A machine according to claim 1 configured tomake smoking articles that comprise a rod of smokeable material with afilter attached at one end, and including first and second reject pathsextending from the filter removal device to receive the filters and therods of smokeable material respectively of the smoking articlesidentified for rejection at the inspection station.
 3. A machineaccording to claim 2 wherein the rod of smokeable material comprises abody of smokeable material received within a cylindrical wrapper ofsheet material, and including a cutter to cut the wrapper, and aseparator to separate the smokeable material from the wrapper forre-use.
 4. A machine according to claim 3 wherein the separatorcomprises a mesh to pass the smokeable material but not the wrapper. 5.A machine according to claim 3 wherein the separator comprises acentrifuge.
 6. A machine according to any preceding claim wherein theinspection station includes a rotary inspection drum to receive smokingarticles around its periphery aligned with its axis of rotation, adetector to detect characteristic of the smoking articles, a processorto make a comparison of the detected characteristic with thepredetermined criterion, and a diverter responsive to the outcome of thecomparison to route the smoking articles along an accept path or areject path selectively.
 7. A machine according to claim 6 wherein thefilter removal device is configured to remove the filters of smokingarticles moving along the reject path.
 8. A machine according to anypreceding claim wherein the filter removal device comprises a cuttingblade.
 9. A machine according to any preceding claim wherein filterremoval device is configured to remove filters so that they remainintact after removal.
 10. A device to be retrofitted to a machine formaking smoking articles that include filters, the machine comprising aplurality of fabrication stations configured in a production line toperform sequential steps in the manufacture of the smoking articles withfilters, and an inspection station on the production line to receive theso manufactured smoking articles sequentially and to identify those ofthe smoking articles that are to be rejected as a result of not meetinga quality control criterion, the device comprising: a filter removaldevice to be retrofitted to the production line such as to remove thefilters from the smoking articles identified for rejection at theinspection station.
 11. A device according to claim 10 including arejection drum to receive the rejected smoking articles that comprise arod of smokeable material with a filter attached, and a cutter to cutthe rod of smokeable material so as to separate the filter whilst insitu on the rejection drum.
 12. A method of recovering smokeablematerial from smoking articles performed with the use of a machine asclaimed in any one of claims 1 to
 10. 13. A method of making smokingarticles that include filters, utilising a plurality of fabricationstations configured in a production line to perform sequential steps intheir manufacture, receiving the so manufactured smoking articlessequentially at an inspection station on the production line,identifying at the inspection station those of the smoking articles thatare to be rejected as a result of not meeting a quality controlcriterion, and utilising a filter removal device on the production lineto remove the filters from the smoking articles identified for rejectionat the inspection station.
 14. A method according to claim 13 includingcutting the filters from the smoking articles that are to be rejected onthe production line.
 15. A method according to claim 13 includingrecycling smoking material from the rejected smoking articles.